Iron and Steel 1

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1. What are the materials that fall into the category of ferrous metals?
2. What is the density limit between light metal and heavy metal?
3. How many states of the materials?
4. Explain the thermal expansion of metal, liquid and gas?
5. Explain the term melting temperature – freezing temperature?
6. Explain the term boiling temperature – condensation temperature?
7. Find out the density and melting temperature of the solid material such as: Aluminum (Al), Cast
iron, Chromium (Cr), Copper (Cu), Gold (Au), Lead (Pb), Magnesium (Mg), Silicon (Si), Silver
(Ag), Iron (Fe), steel and Zinc (Zn)?
8. Find out the density and specific heat of liquid material such as: Diesel fuel, Gasoline, Mercury
(Hg) and water?
9. Find out the density and specific heat of gaseous materials such as : Acetylene (C2H2), Air,
Carbon dioxide (CO2), Nitrogen (N2) and Oxygen (O2)?
10. What are the properties and application of materials such as : Acetone, Acetylene, Sulfuric
acid, Ethy alcohol?
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 Iron ore:
 The two most important minerals
in these deposits are iron oxides:
hematite (Fe2O3) and magnetite
(Fe3O4).
 These iron ores have been mined
to produce almost every iron and
steel object that we use today -
from paper clips to automobiles
to the steel beams in skyscrapers.

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 Blast furnace:
 A blast furnace is a type of metallurgical furnace used for smelting to produce
industrial metals and its alloys, generally iron, but also others such as lead or
copper.
 In a blast furnace fuel(coke), ores (iron ore), and flux (limestone) are continuously
supplied through the top of the furnace, while a hot blast of air (sometimes with
oxygen enrichment) is blown into the lower section of the furnace through a series
of pipes called tuyeres, so that the chemical reactions take place throughout the
furnace as the material moves downward.
 The end products are usually molten metal and slag phases tapped from the
bottom, and flue gases exiting from the top of the furnace. The downward flow of
the ore and flux in contact with an upflow of hot, carbon monoxide-rich combustion
gases is a countercurrent exchange and chemical reaction process.

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Video:
https://www.youtube.com/watch?v=LM4VOW6xZ5Y 25
 Blast furnace main products:
 Pig iron: Density 6.7 to 7.3kg/dm3, melting point approx. 1300oC, carbon content
up to 6%.
 Blast furnace by-products:
 Slag: consists of silicaceous lime and is used for construction purposes (blast
furnace cement, slag stone, slag wool).
 Throat gas: contains about 24% carbon monoxide and also carbon dioxide,
hydrogen and nitrogen. It is flammable, and is used as a fuel for the air heaters, for
miscellaneous heating purpose, as a fuel gas for gas engines and to heat the coke
chambers.

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1. What is iron ores?
2. How ores are classified?
3. What are the important iron ore?
4. What is the role of blast furnace?
5. Write down the chemical equation happening in blast furnace and brief explain?
6. What are the final product of blast furnace?

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 Steel:
 Steel is the most common metal alloy
in the world. In its simplest form, it
consists of iron and varying amounts
of carbon.
 Iron is the major component of steel,
with carbon being a distant second,
at between 0.02% - 2.14%,
depending on the grade.
 Steel is well-known for its strength,
which is given to it precisely by the
alloying elements.

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 Cast iron:  Cast iron tends to be brittle, (except for
malleable cast irons).
 With its relatively low melting point,
good fluidity, castability, excellent
machinability, resistance to
deformation and wear resistance, cast
irons have become an engineering
material with a wide range of
applications.
 Cast irons are used in pipes, machines
and automotive industry parts, such as
cylinder heads, cylinder blocks and
gearbox cases and as the decorative
furniture such as fences, chairs...

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 Cast iron production:
 Cast iron is made from pig iron, which is the product of smelting iron ore in a blast
furnace.
 Cast iron can be made directly from the molten pig iron or by re-melting pig iron,
often along with substantial quantities of iron, steel, limestone, carbon (coke) and
taking various steps to remove undesirable contaminants.
 Cast iron is sometimes melted in a special type of blast furnace known as a cupola,
but in modern applications, it is more often melted in electric induction furnaces
or electric arc furnaces.
 After melting is complete, the molten cast iron is poured into a holding furnace or
ladle.

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1. What is pig iron?
2. What is the different between grey pig iron and white pig iron?
3. What is steel?
4. What is the term “refining” means?
5. How cast iron is produced?
6. How is steel classified?
7. What does it mean by the term “High grade steel”?
8. What is unalloyed steel? Low alloyed steel? High alloyed steel?
9. What are the main alloyed components of steel?

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1. Explain the steel making by the oxygen conversion process?
2. Explain the steel making by the Siemen-martin process?
3. Explain the steel making by the electric arc furnace process? What type of steels
can be produced by this process?

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1. What is monoblock casting of steel? What is continuous casting of steel?
2. What does this designation means in DIN standard: GG, GGG, GH?
3. Explain the diagram on page 53 about processing pig iron to obtain casting
materials?

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Q&A
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